Last Updated on June 11, 2025 by Packoi Team
But as adoption rises, so do concerns. Critics argue that flexible packaging, often made from layers of plastic, foil, and other non-biodegradable materials, poses a significant threat to the environment. With recycling infrastructure lagging behind innovation, the conversation around sustainability is heating up.
We’ll evaluate the true environmental impact of flexible packaging, highlight where it stands in the bigger picture of sustainability, and debunk some of the most common myths.
Is Flexible Packaging Sustainable?
Sustainability isn’t a simple yes-or-no label, especially when it comes to packaging. Flexible packaging occupies a complex intersection of innovation, efficiency, and environmental responsibility. To determine its true sustainability, we need to zoom out and consider its entire life cycle.
First, the materials. Flexible packaging typically uses less raw material than rigid alternatives like glass, metal, or thick plastic. That means lower energy demands during production and fewer greenhouse gas emissions from the outset.
Its lightweight structure also makes a big difference during transportation. Less weight equals less fuel burned, and fewer trucks are needed to move the same volume of goods.
But disposal is where things get tricky. While flexible packaging often extends shelf life (cutting down on food waste, which itself has a heavy environmental cost), most curbside recycling systems aren’t equipped to handle it.
Multi-layer laminates are difficult to separate and process. This contributes to landfill build-up and undermines circular economy goals.
When compared to rigid packaging, however, the picture becomes more nuanced. For example, producing a glass jar takes significantly more energy and emits more CO₂ than a plastic pouch. And if that pouch reduces product waste and transport emissions, its overall environmental footprint may be lower, despite not being widely recyclable.
The question, then, isn’t just whether sustainable packaging is sustainable. It’s “Sustainable compared to what, and under what conditions?” Understanding that trade-off is key to unlocking smarter, future-ready packaging solutions.
Ready to Get Custom Packaging for Your Business?
start with a low minimum order quantity
Common Myths About Flexible Packaging and the Environment
Flexible packaging often gets a bad rap. But many of the concerns surrounding it are based on outdated or incomplete information. Let’s take a closer look at some of the most common myths and what the facts actually reveal.
Myth 1: All Flexible Packaging Is Plastic and Harmful
The word “flexible” often conjures images of single-use plastics. These may include snack bags, wrappers, and squeeze tubes.
Such products are seen as symbols of throwaway culture. As public awareness of plastic pollution rises, it’s easy to believe that all flexible packaging is part of the problem.
There’s also confusion around the term itself. Because flexible packaging includes so many formats, people often lump it into one broad category. That leads to generalizations and, ultimately, misinformation about its material makeup and potential for harm.
Debunked
Yes, much of today’s flexible packaging includes plastic. But that’s not the whole story. Some formats integrate paper, aluminum, or biodegradable biopolymers.
Emerging materials are moving beyond petroleum-based plastic. Bio-based films and compostable laminates are already in production. Plus, material scientists are engineering recyclable mono-material options to replace complex multi-layer versions.
Myth 2: It’s Never Recyclable
Many people assume flexible packaging is unrecyclable by design. Since it’s not accepted in most blue bins, the logic goes, it must be inherently incompatible with recycling systems.
There’s also confusion caused by a lack of clear labeling. When consumers don’t know whether something is recyclable, they often assume it’s not.
Debunked
While recycling flexible packaging is still a challenge, it’s far from impossible. Store drop-off programs already accept certain types, like polyethylene-based pouches and bags. These are turned into products like composite lumber or new packaging film.
Progress is accelerating. Brands are designing flexible packaging to work within a circular economy. From mono-material films to return-to-store initiatives, the goal is to make recyclability a standard, not a bonus.
Myth 3: It Always Ends Up in Landfills
There’s a common belief that all flexible packaging, regardless of type, ends up buried in landfills. The assumption comes from the reality that most municipal systems don’t recover flexible packaging efficiently.
The idea that its disposal path is fixed reinforces skepticism about its environmental value, especially when compared to more traditional materials like glass or aluminum.
Debunked
Yes, landfill is still the endpoint for much of today’s flexible packaging. But that doesn’t mean it’s always the worst outcome. Compared to rigid materials, flexible formats use far less space, weight, and energy throughout their lifecycle.
They also reduce product waste. A resealable pouch that extends a food item’s shelf life may prevent more environmental damage than it causes. Some estimates show that food waste has a larger carbon footprint than packaging itself.
Myth 4: Sustainable = Compostable Only
Many consumers associate “eco-friendly” with compostable packaging. If it doesn’t break down in soil or backyard bins, it’s seen as wasteful. Compostable has become a catch-all label for sustainability, especially in food service and retail.
This belief has created pressure for brands to switch to compostables, even when they may not perform well for certain products.
Debunked
Compostables need specific industrial conditions to break down effectively. If they’re tossed into landfills or regular recycling bins, they often behave like traditional plastics.
Moreover, not all products are compatible with compostable materials. Items requiring high-barrier protection for moisture, oxygen, or light may fail when wrapped in compostable film. That leads to spoilage and more waste.
Types of Sustainable Flexible Packaging Materials
There are several types of sustainable flexible packaging materials. Some of them are as follows.
Recyclable Mono-Material Films
Monomaterial films, such as polyethylene (PE) and polypropylene (PP), are designed for easier recycling. Unlike multilayer laminates, these films use a single polymer type, making them compatible with existing recycling streams. Their design reduces contamination and increases the likelihood of successful material recovery.
Compostable Films
Compostable flexible packaging is ideal for short shelf-life products. Materials like PLA (polylactic acid) and cellulose-based films break down in industrial composting environments.
While promising, they must be properly disposed of in the right facilities. Home composting rarely meets the needed conditions.
Bio-Based vs Petroleum-Based Films
Bio-based films are made from renewable sources like cornstarch or sugarcane. They offer a lower carbon footprint during production compared to petroleum-based plastics.
However, being bio-based doesn’t automatically mean the material is compostable or recyclable. End-of-life design still matters.
Certifications to Look For
Credible certifications help verify sustainability claims. TÜV Austria and BPI confirm composability according to recognized standards.
The How2Recycle label provides clear recycling instructions and categorizes packaging by local capability. These certifications empower brands and consumers to make better-informed decisions.
Recyclable vs. Compostable vs. Traditional Flexible Packaging
The following table shows the differences between recyclable, compostable, and traditional flexible packaging.
| Criteria | Recyclable Flexible Packaging | Compostable Flexible Packaging | Traditional Flexible Packaging |
|---|---|---|---|
| End-of-life impact | Can be reprocessed into new materials if collected properly | Breaks down into organic matter under industrial conditions | Typically landfilled or incinerated; minimal recovery |
| Infrastructure required | Needs store drop-off or specialty recycling streams | Requires access to industrial composting facilities | Uses general waste systems; rarely recovered |
| Shelf life & performance | Good for dry goods; improving for wet or barrier needs | Limited protection; best for short shelf-life products | Strong barrier properties; supports long shelf life |
| Cost considerations | Moderate and becoming more cost-effective | Often higher due to limited supply chain | Lowest cost due to mature, established systems |
| Best use cases | Snacks, e-commerce, personal care, and pet food | Local food items, cafes, events, and eco-conscious packaging | Frozen foods, pharmaceuticals, and vacuum-sealed products |
Recyclable flexible packaging is best for businesses seeking scalable circular solutions and aiming to align with future infrastructure. It’s practical for consumer goods and dry snacks, with rapidly improving recyclability.
Meanwhile, compostable packaging is ideal for short shelf-life products or brands focused on zero-waste events, local food markets, or single-use items where composting is available. However, it requires specific disposal systems and may not suit high-barrier needs.
Challenges to Making Flexible Packaging More Sustainable
The following challenges make it difficult to make flexible packaging more sustainable.
- Recycling Infrastructure Gaps: Most flexible packaging requires specialized collection systems. Curbside recycling rarely accepts films, limiting access to mechanical recycling. This breaks the circular economy potential for many formats.
- Consumer Confusion and Contamination: Lack of clear disposal guidance leads to packaging waste ending up in landfills. Mixed materials often contaminate recycling streams, undermining environmental efforts.
- Complex Supply Chains and Multi-Layer Materials: Flexible materials often combine several layers to preserve shelf life. These composites are difficult to separate, making life cycle assessment and recycling more complicated than for rigid materials.
- Greenwashing and Mislabeling Risks: Claims of composting or recyclability can mislead buyers. Without clear certification, brands risk overstating environmental benefits and eroding trust.
- Balancing Performance with Sustainability: Flexible packaging requires high-function barriers to reduce food waste. Yet improving environmental outcomes while maintaining performance remains a challenge.
Despite these challenges, innovation is moving fast. Smarter design, clearer labeling, and better infrastructure are key to unlocking flexible packaging’s true sustainable potential.
How Businesses Can Make the Switch to Sustainable Flexible Packaging?
When it comes to switching to sustainable, flexible packaging, businesses must follow the following best practices for results.
Conduct Packaging Audits
Start by conducting thorough packaging audits to assess current materials, volumes, and life cycle impacts. Focus on high-volume SKUs where changes can deliver the biggest carbon footprint reductions. Products using poly mailers or grocery bags are ideal starting points. Plus, grocery bags are commonly used, so they make a bigger impact.
Start with High-Volume SKUs
Prioritize switching packaging for your most commonly sold products, such as poly mailer boxes. This approach maximizes environmental benefits quickly and builds momentum for broader changes.
Work with Eco-Focused Converters and Suppliers
Partner with suppliers who specialize in sustainable packaging solutions. Many leading companies are investing in compostable films and recyclable mono-materials that support home and industrial composting. These materials offer a viable alternative to traditional multi-layer flexible packaging and are very lightweight.
Communicate Clearly with Consumers
Transparent communication about packaging changes builds consumer trust. Educate customers on how to properly dispose of new materials to support environmental stewardship.
Use Clear, Certified Labeling
Adopt clear, certified labels indicating compostability or recyclability. These labels empower consumers to make informed disposal decisions, reducing contamination and waste.
Transitioning to sustainable, flexible packaging requires a phased approach. By conducting packaging audits, prioritizing high-volume SKUs, collaborating with eco-conscious converters, and clearly communicating with consumers, businesses can drive environmental impact.
Certified labeling further reinforces transparency and trust, helping consumers participate in the sustainability journey.
FAQs
Can flexible packaging be recycled in curbside bins?
Most curbside programs do not accept flexible packaging due to its very thin films and multiple layers, which complicate recycling. These materials often contain mixed polymers that require specialized facilities.
What’s the difference between biodegradable and compostable film?
Biodegradable films break down over time but may leave harmful residues or require specific conditions. Compostable films, however, decompose fully into non-toxic elements in industrial or home composting facilities.
Is flexible packaging better than rigid packaging environmentally?
Flexible packaging often uses less material and requires less energy to produce and transport, resulting in a smaller carbon footprint. Its very lightweight nature reduces emissions in the supply chain. However, recycling rates can be lower compared to rigid packaging.
Conclusion
Flexible packaging is not inherently unsustainable; its impact depends on thoughtful design, material choice, and proper disposal methods. Thanks to ongoing innovations, flexible packaging is becoming more recyclable, compostable, and eco-efficient.
However, achieving true sustainability requires key stakeholders to make informed decisions and consumers to be educated on proper use and disposal.
Call to Action
Looking to adopt eco-friendly flexible packaging for your brand? Packoi is a sustainable material supplier that provides alternatives that meet business and environmental goals. Contact now!
